TIG Welder Consumables

Last modified on February 5th, 2023

TIG welding consumables come in a variety of types and sizes, dependant on the type of material you’re welding and its size (thickness). Then there’s the individual differences. i.e. If you’re purchasing back caps, they can be supplied as small, medium or long.

The consumables can also be split into three distinct groups:

• Filler Wire (or Rods).
• TIG Torch Parts and Accessories.
• Shielding Gas.

Note:

• The consumables must also fit the type of TIG torch you’re using.

Topics on this Page:

• TIG Welding Consumables (General Information):
• Which Consumables Fit my Tig Torch?
• The Different Consumables (in more detail):
• Image Gallery:

---

TIG Welding Consumables (General Information):

There are many parameters you need to consider when buying TIG consumables.

• The type of material(s) to be welded.
• The thickness of the material to be welded.
• The filler rods and their compatibility.
• The type of welded joint.
• The different variations of the interchangeable ‘consumable’ parts (and do they fit the torch?).

TIG Welding – Material Thickness, Current, Consumable Sizes (A rough guide):

TIG Welding – Consumable Cross Reference Guide1
Material Thickness			Amps		Size (mm)
mm	Inch	Gauge	DC	AC	Filler Rod	Tungsten	Gas Cup
0.50	1/64	24	5-20	5-15	1.02	1-1.6	3-5
0.65	1/32	22	10-35	10-30	1.02	1-1.6	3-5
0.80	1/32	20	20-50	25-45	1.02	1-1.6	4-5
1.00	3/64	18	25-80	45-60	1.0	1-1.6	4-5
1.30	3/64	16	40-90	50-100	1.0	1.6	4-6
1.60	1/16	14	60-100	50-100	1.6	1.6	4-6
2.40	3/32	11	85-125	90-150	1.6-2.4	1.6	4-6
3.20	1/8		100-135	125-190	1.6-2.4	2.4	4-6
4.00	5/32		125-175	180-200	2.4	2.4	5-7
4.80	3/16		150-225	180-240	3.2	2.4	7-8

Reference:

• ¹ Due to the many different parameters (the type of material, its size, the type of joint, etc, etc), the table above should be considered as a very rough guide:
• ² Tig filler rods are generally sold in sizes from 1.0mm and upwards (aluminium 1.6mm). If you want a smaller size wire, MIG wire is often used.

Notes:

• Always follow the manufacturer’s warnings, instructions, and their Material Safety Data Sheet (MSDS). Welding fumes and dust can affect your health.

---

Which Consumables Fit my TIG Torch?

There range of consumables can be purchased in different sizes, configurations, types and for different materials! Therefore, it’s important to know which parts you want. The links below give more detailed information on all the different types of part (consumables) available and the various different configurations…

• TIG Welding Gun (Torch) – The Different Types:
• The Different Consumables (In more detail):

As an illustration:

TIG Torch Fittings Thread – Gas Cups (Nozzles) to Collet Body to Torch
Cooled by:	TIG Torch		Ceramic Cup (Nozzle) Thread		Collet Body to Torch Thread
	Type1	Group	Standard2	Stubby2
Air	WP-17	A	13/32 UNS	3/4 UNF	3/8″ UNF
Air	WP-26
Water	WP-18
Air	WP-9	B	3/8″ UNF	9/16 UNF	5/16″ UNF
Water	WP-20

---

The Different Consumables (In more detail):

The topics listed below, will hopefully make it easier to understand what the differences are between the various TIG welding consumables, and make it easier to obtain the correct items for the job in hand.

The three distinct groups of TIG consumables: (links open in a new tab)…

1. TIG Filler Wire (or Rods):

• TIG Filler Rods (Filler Wire):

2. TIG Torch Parts and Accessories (Consumables):

• Tungsten Electrodes:
• TIG Collet Body (Gas Lens):
• Collets:
• Gas Cup (Ceramic and others):
• Heat Shield (or Insulator):
• O’Rings:
• Back Caps:

3. TIG Shielding Gas:

• Shielding Gas:

---

Image Gallery:

– click or tap any image to view full size –